Wärtsilä 20DF Engine O&MM 12.

Cylinder head with valves

12. Cylinder head with valves

The cylinder head is fitted with:
● Rocker arm assembly (3, see Figure 12-1)
● Inlet (4) and exhaust (2) valve assemblies
● Fuel injector
● Knock sensor (5)
● Pilot fuel injector (6)
● Cylinder pressure sensor (7), if equipped
● Fuel injector cooling pipe, if equipped
The charge air, exhaust gas and cooling water connections are integrated in a multiduct.

1 Valve yokes 5 Knock sensor

2 Exhaust valve assembly 6 Pilot fuel injector
3 Rocker arm assembly 7 Cylinder pressure sensor (if equipped)
4 Inlet valve assembly
Fig 12-1 Cylinder head with equipment

12.1 Cylinder head

The cylinder head is made of cast iron. It is positioned with engine block studs and secured by
hydraulically tightened nuts. A gasket seals the cylinder head to the cylinder liner. The cylinder
head drillings allow inlet and exhaust gases, cooling water, and oil to flow during engine
operation.
The cylinder head's flame plate is a part of the combustion chamber. During the combustion,
the flame plate is exposed to high charge pressure and temperatures. Combustion air is led
from the air receiver through the multiduct and the cylinder head inlet channel into the cylinder.

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12. Cylinder head with valves Wärtsilä 20DF Engine O&MM

The air flow is governed by two inlet valves in the flame plate. Similarly, the exhaust gas is led
from the cylinder through the cylinder head exhaust channel to the exhaust manifold. The
exhaust gas flow is also governed by two valves.
The fuel injector and its centre sleeve are centrally mounted in the cylinder head. The centre
sleeve holds the fuel injector in position and separates the fuel injector from the cooling water.
The pilot fuel injector is of the electronic solenoid operated design and controlled by the engine
control and monitoring system. It is fastened by a clamping jaw and sealed by a copper washer
in a bore on the side of the cylinder head.
Each cylinder head is individually cooled by a water flow entering the cylinder head from the
cylinder jacket. Cooling passages are drilled into the exhaust valve seats. The cooling water
is collected to a single flow after passing the flame plate and the seat rings. The cooling water
flows out from the cylinder head through the multiduct. Any possible air or gas in the cooling
water is vented from the top of the multiduct.
The valve mechanism is lubricated by the lubricating oil system. The oil is led through the rocker
arm bracket assembly to the rocker arm bearings, yokes and the valve rotators. Part of the oil
is used for valve and valve guide lubrication and fuel injector cooling (if equipped).

12.1.1 Maintaining the cylinder head

Tools

Code Description

836 006 Cylinder head service trestle

Use the service trestle to turn the cylinder head during maintenance.

Fig 12-2 Cylinder head service trestle

● Clean the cooling water spaces with chemical solvents.

Scale formation in the cooling spaces affects the cooling efficiency.

For more information about chemical cleaning, contact Wärtsilä.

● Inspect the combustion spaces.

● Inspect the valve guides, valve seats and centre sleeve for wear and damage.

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Wärtsilä 20DF Engine O&MM 12. Cylinder head with valves

Replace the components, if necessary.

● Renew the sealing rings at every overhaul.
● Inspect and clean the sealing surfaces between the cylinder head and cylinder liner.
If necessary, recondition them using special tools or contact Wärtsilä.

12.1.2 Removing the cylinder head

Prerequisites
● Drain the gas system by closing the gas valves and opening the gas ventilation valve.
● Drain the cooling water.
● Shut down the prelubricating oil pump.
● Shut down the fuel supply.
● Disconnect the gas admission valve power cable.
● Disconnect the cylinder pressure sensor (if equipped).

Tools

Code Description

806 024 Wrench for multiduct

806 025 Wrench for multiduct

808 001 Indicator valve T wrench

832 004 Cylinder head lifting tool

836 006 Service trestle for cylinder head

861 025 Turning pin

861 156 Distance sleeve

861 158 Hydraulic cylinder tool set - Complete

861 159 Hydraulic cylinder

861 161 High-pressure pump

861 164 Flexible hoses

861 165 Flexible hoses

Procedure
1 Remove the protective caps from the cylinder head nuts (9).

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12. Cylinder head with valves Wärtsilä 20DF Engine O&MM

1 Protection sleeve 7 Rocker arm assembly

2 Fuel injector pipe 8 Cylinder head cover
3 Hotbox cover 9 Cylinder head nut
4 Pilot fuel injector 10 Main gas admission valve
5 Fuel injector connection pipe 11 Multiduct side bolt
6 Push rod 12 Multiduct
Fig 12-3 Cylinder head components

2 Remove the cylinder head cover (8) and hotbox cover (3).
Carefully withdraw any sensor cables through the cylinder head cover.
3 Rotate the flywheel using the turning device until both the inlet and exhaust valves are
closed on the cylinder to be worked on.
4 Remove the fuel injector cooling pipe (if equipped), the rocker arm assembly (7) and the
push rods (6).
5 Remove the main gas admission valve assembly (10).
See Chapter 17 Fuel system.
6 Remove the multiduct bolts (11) using the wrench.
7 Remove the fuel injector pipe and all the other necessary pipes.
Protect all the pipe openings.
8 Disconnect the knock sensor and pilot fuel injector cables.
9
WARNING
Hydraulic tools generate high forces and pressure. Incorrect use can result in serious injury
or property damage.
● Check that the hydraulic tools are in proper condition. Do not use damaged hydraulic tools.
● Pay attention to the hydraulic tools setup. Read the hydraulic tool operating instructions
before usage.
● Use the stated hydraulic loosening pressure.
● Use proper personal protective equipment (PPE).

Connect the hydraulic tools and loosen the cylinder head nuts.
See Chapter 07 Tightening torques and use of hydraulic tools.

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10 Remove the cylinder head nuts.

11 Remove the cylinder head.
a Mount the cylinder head lifting tool (2).

1 Location pin 4 Lifting hook

2 Lifting tool 5 Cylinder head
3 Retaining bolt
Fig 12-4 Lifting the cylinder head

b Lift off the cylinder head and remove the push rod protection sleeves.
c Place the cylinder head on the cylinder head service trestle.

12 Cover the cylinder opening with a piece of plywood or similar.

13 Mount the protective caps to protect the cylinder head stud threads.

12.1.3 Mounting the cylinder head studs

Prerequisites
Inspect the cylinder head studs for corrosion.
● If the corrosion pits are less than 0.1 mm deep, polish the pits with a small hand grinder.
● If corrosion pits deeper than 0.1 mm are found, replace the stud.

Corrosion depth in threads can be hard to determine. Replace the studs whenever
in doubt.

Tools

Code Description

803 016 Stud remover M36

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12. Cylinder head with valves Wärtsilä 20DF Engine O&MM

Procedure
1 Lubricate the stud threads (3).
Use a thin layer of Mobilarma 524 or corresponding corrosion protection agent.

1 Sealing ring
2 Space between stud and engine block
3 Stud threads
Fig 12-5 Mounting the cylinder head studs

2 Fit the stud and tighten it with the stud remover to the stated torque.
See Chapter 07 Tightening torques and use of hydraulic tools.
3 Fill the space between the stud and engine block (2) with corrosion protection agent.
Use Mobilarma 524 or corresponding corrosion protection agent.
Leave an approximately 2 mm space between the sealing ring and the corrosion protection
agent.
4 Mount the sealing ring (1).

Renew the sealing ring at every piston overhaul.

12.1.4 Mounting the cylinder head

Tools

Code Description

806 204 Wrench for multiduct

806 205 Wrench for multiduct

808 001 Indicator valve T wrench

832 004 Cylinder head lifting tool

848 001 Feeler gauge set

861 025 Turning pin

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Continued from previous page

Code Description

861 156 Distance sleeve

861 158 Hydraulic cylinder tool set - Complete

861 159 Hydraulic cylinder

861 161 High-pressure pump

861 164 Flexible hoses

861 165 Flexible hoses

Procedure
1 Clean the sealing surfaces of the cylinder head and the multiduct.
2 Fit new gaskets for the cylinder head and the multiduct.
3 Mount the cooling water sealing rings to the engine block and the push rod protection
sleeves.
4 Lift the cylinder head into position.
a Mount the cylinder head lifting tool (2).

1 Locating pin 4 Lifting hook

2 Lifting tool 5 Cylinder head
3 Retaining bolt
Fig 12-6 Lifting the cylinder head

b Lift the cylinder head, and carefully lower it over the engine block studs and into
position.

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12. Cylinder head with valves Wärtsilä 20DF Engine O&MM

NOTICE
Before hydraulically tightening the cylinder head nuts, check that the multiduct gasket is
intact and properly aligned with the cylinder head sealing surface. Improper alignment
can cause water leakage into the cylinder.

5 Screw on the cylinder head nuts and tighten using the turning pin.
6 Fit the multiduct bolts and tighten by hand.
7
WARNING
Hydraulic tools generate high forces and pressure. Incorrect use can result in serious injury
or property damage.
● Check that the hydraulic tools are in proper condition. Do not use damaged hydraulic tools.
● Pay attention to the hydraulic tools setup. Read the hydraulic tool operating instructions
before usage.
● Use the stated hydraulic tightening pressure.
● Use proper personal protective equipment (PPE).

Connect the hydraulic tools and tighten the cylinder head nuts in two stages to the stated
torque.
For tightening torques and use of hydraulic tools, see Chapter 07 Tightening torques and use
of hydraulic tools.
8 Tighten the multiduct bolts to the stated torque using the wrench.
9 Connect the fuel injection pipes and all other removed pipes.
10 Connect the pilot fuel injector and the knock sensor cables.
11 Mount the push rod protection sleeves and push rods.

If the push rod protection sleeves have oil drain holes they must be mounted
upwards.

12 Mount and centralise the rocker arm bracket assembly.

See Chapter 14 Valve mechanism and camshaft.
13 Mount the fuel injector cooling pipe (if equipped).
14 Adjust the valve clearance.
For clearances, see Chapter 06 Adjustments, clearances and wear limits.
15 Mount the main gas admission valve assembly.
See Chapter 17 Fuel system.
16 Mount the cylinder head cover.
Carefully guide any sensor cable(s) through the cylinder head cover.
Renew the hose gasket for the cover, if necessary. Spot glue the gasket in place using Bostik
glue A3.

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Fig 12-7 Glue points

17 Mount the protecting caps for the cylinder head nuts.

Postrequisites
● Connect the cylinder pressure sensor (if equipped).
● Connect the main gas admission valve power cable.
● Fill the engine cooling water system.
● Check for water leakage and monitor the expansion tank level.
● Run the prelubricating oil pump and check for leakage.

12.2 Inlet and exhaust valves

The cylinder head has inlet and exhaust valves. The inlet and exhaust valve heads are of
different size and material. They can be identified by the markings at the top of the valve stem.
The valve stems move in guides. The valve guide has a sealing ring located at the top of the
guide bore. Each valve has a spring and a rotator secured by two cone-shaped cotters.
The cylinder head is fitted with inlet and exhaust valve seat rings.
The exhaust valve seat rings are fitted with a sealing ring.

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12. Cylinder head with valves Wärtsilä 20DF Engine O&MM

1 Cotters 5 Valve guide

2 Lip seal 6 Valve
3 Valve rotator 7 Inlet valve seat ring
4 Valve spring 8 Exhaust valve seat ring
Fig 12-8 Inlet and exhaust valves

12.2.1 Dismantling the inlet and exhaust valves

Prerequisites
● Remove the cylinder head.
● Remove the fuel injector.
● Remove the pilot fuel injector.
● Remove the knock sensor.
● Remove the cylinder pressure sensor (if equipped).

Tools

Code Description

830 001 Fuel injector extraction tool

836 006 Cylinder head service trestle

837 030 Valve guide extraction tool

846 010 Valve spring compression tool

Procedure
1 Mount the valve spring compression tool and tighten the securing bolt (3) to the cylinder
head.

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Wärtsilä 20DF Engine O&MM 12. Cylinder head with valves

1 Adjusting bolt 4 Locating pin

2 Valve spring compression tool 5 Valve cotters
3 Securing bolt
Fig 12-9 Tool assembly for compressing the valve springs

2 Remove the valve cotters, valve rotators and valve springs.

a Compress the springs about 15-20 mm with the adjusting bolt (1).
b Knock at the centre of the valve discs with a soft piece of wood or a plastic hammer.
This loosens the valve cotters (5) for removal.
c Loosen the adjusting bolt to unload the spring compression tool.
d Remove the valve rotators and springs.
e Keep each set of valve cotters, valve rotators and valve springs separate.

NOTICE
Do not damage the valve spring coating.

3 Mark the valves and other components so that they can be remounted into the same
positions.

Mark the valves with a felt marker only.

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 12. Cylinder head with valves Wärtsilä 20DF Engine O&MM

1 Air in
2 Inlet valves marked A and B
3 Exhaust valves marked C and D
4 Exhaust out
Fig 12-10 Marking the valves (view from the underside)

12.2.2 Checking and reconditioning

12.2.2.1 Inspecting the valves and seat rings
Tools

Code Description

841 001 Valve grinding tool

Procedure
1 Clean the valves, seat rings, ports, valve guides and the underside of the cylinder head.
2 Inspect the valve surfaces.

Lapping is not allowed for Nimonic exhaust valves (Nimonic valves are
non-magnetic).

The valve surfaces should not have any scratches or notches, especially on the
area marked with 'a'.

If the inlet valves have only slight signs of pitting, lap them by hand.

If there are areas of non-contact or pitting, machine-grind the valve discs and valve seats.
3 Measure the burn-off (z) on the valve disc, allowable diameter (d2) and the minimum and
nominal values (y).

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 Wärtsilä 20DF Engine O&MM 12. Cylinder head with valves

1
y z

d2

1 Burn-off area
Fig 12-11 Inspecting the valves

See measurement record 2012V015.

Compare the measured values against the values specified in Section 12.2.2.4. If the values
exceed the limits, replace the valve.
4 Measure the valve stem and valve guide.
Compare all measured values against the values specified in the clearance and wear limit
table. See Chapter 06 Adjustments, clearances and wear limits.
If the values exceed the limits, replace the worn part. Otherwise, recondition the valves and
valve seat rings.

If reconditioning or replacing the seat rings, recondition or replace also the valves,
and vice versa.

12.2.2.2 Mounting the valve guide lip seal

Tools

Code Description

846 061 Mounting tool for lip seal

1 Lubricate the inside of the lip seal (2, see Figure 12-8) and the upper part of the valve
guide with oil.
2 Carefully push the lip seal on top of the valve guide using the mounting tool.
There is a groove on the valve guide and corresponding ridge in the lip seal. When the lip seal
is in correct position there might still be a small gap between the lower edge of the lip seal and
the valve guide. Do not use excessive pressure to push the lip seal in place.

NOTICE
Check that the lip seal is straight and not tilted in relation to the valve guide.
Take care not to damage the spring on the lip seal.

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 12. Cylinder head with valves Wärtsilä 20DF Engine O&MM

12.2.2.3 Lapping the valves

Tools

Code Description

836 006 Cylinder head service trestle

841 001 Lapping tool

If there are signs of pitting on the inlet valve and valve seat ring faces, lap them
manually using the lapping tool.

Procedure
1 Mount the lapping tool onto the valve.

1 Clamping bolt
2 Clamping jaws
3 ½-drive socket
4 Speed brace
Fig 12-12 Lapping the valves

2 Apply a thin layer of lapping compound to the valve's sealing surface.

Use No. 1 for coarse lapping and No. 3 for fine lapping.
3 Rotate the valve back and forth in the valve seat with the lapping tool.
While lapping, lift the valve from the seat periodically.

Lap the valve surface taking off a minimum amount of material. It is not necessary
to lap off all pits.

Postrequisites
After lapping, clean the valve and the seat.

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 Wärtsilä 20DF Engine O&MM 12. Cylinder head with valves

12.2.2.4 Machine-grinding valves and seat rings

Use the special tools available from Wärtsilä. For more information about grinding,
see the instructions delivered with the tools.

The valves and the seat rings can only be machined until the allowable diameters
are reached. After the limits have been exceeded, renew the valves and seat rings.

Procedure
1 Grind the inlet valves and seat rings.

d2

z2

D1
z1

d2. Inlet valve minimum allowable diameter

Z1. Inlet valve angle
Z2. Inlet valve seat angle
D1. Inlet valve seat allowable diameter
Fig 12-13 Inlet valve and seat ring

Table 12-1 Inlet valve measurement

Component Wear limit [mm] Angle [ ° ]

Max Min

Inlet valve [d2] 52 20.05 19.95

Inlet valve seat ring [D1] 78 20.05 19.95

2 Grind the exhaust valves and seat rings.

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 12. Cylinder head with valves Wärtsilä 20DF Engine O&MM

d2

z2

D2

z1

d2. Exhaust valve minimum allowable diameter

Z1. Exhaust valve angle
Z2. Exhaust valve seat angle
D2. Exhaust valve seat allowable diameter
Fig 12-14 Exhaust valve and seat ring

Table 12-2 Exhaust valve measurement

Component Wear limit [mm] Angle [ ° ]

Max Min

Exhaust valve [d2] 48 30.10 30.00

Exhaust valve seat ring 68.6 30.10 30.00

[D2]

12.2.2.5 Checking the valve contact surfaces

Check the valve contact surfaces with a blueing test.

Ensure that the valve and valve seat that are blue-tested are assembled as a
matched pair.

Procedure
1 Clean the valve contact surfaces.
2 Spread a thin layer of Prussian blue on the valve contact surfaces.
If the applied layer of Prussian blue is too thick, the test results are not accurate.
3 Mount the valve in the valve guide. Press the valve gently against the valve seat.

Do not fully rotate the valve while it is seated.

Repeat two or three times, lifting the valve and turning it about 45° between the strokes.
4 Check the contact areas.
5 If the obtained contact area is only partly blue:
a Machine-grind the valve seat ring again to adjust the cutting angle.
b Repeat the blueing test.

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12.2.3 Fitting the inlet and exhaust valves

Prerequisites
● Check that the contact surfaces of the springs and valve rotators are undamaged and clean.
● Check the valve springs and valve rotators for cracks and wear marks. Replace them, if
necessary.

Tools

Code Description

846 010 Valve spring compression tool

Procedure
1 Clean the valve guides thoroughly and renew the sealing rings.
2 Lubricate the valve stems with clean engine oil.
3 Clean the valve seat surfaces.
4 Mount the valves in their original locations and check that the valves move freely.
5 Install the valve springs, spring discs and valve rotators.
6 Mount the valve spring compression tool.

1 Adjusting bolt
2 Valve cotters
Fig 12-15 Tool assembly for compressing the valve springs

7 Compress the valve springs by tightening the adjusting bolt (1).

8 Lubricate the valve cotters (2) lightly with clean engine oil.
9 Mount the valve cotters.
a Put in the valve cotters and unload the springs by loosening the adjusting bolt (1)
slowly.

While unloading the springs, check that the valve cotters fit properly and that
the clearances between the two valve cotter halves are equal.

b Remove the valve spring compression tool.

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12. Cylinder head with valves Wärtsilä 20DF Engine O&MM

10 Check the valve rotators' operation.

a Put a mark on the valve rotators and a corresponding mark on the cylinder head.
b Gently hit on the valve stem with a non-recoiling hammer to check the rotation.

NOTICE
Be careful not to damage the valve rotators.

12.2.4 Adjusting the valve yoke

Prerequisites
● Disconnect the cylinder pressure sensor cable (if equipped).
● Remove the cylinder head cover.

NOTICE
Incorrect adjustment of the valve yoke may cause serious damage.

Adjust the valve yoke only after the engine has cooled down.

Procedure
1 Use the turning device to rotate the flywheel to TDC at firing of the cylinder concerned.
Both push rods should rotate freely.
2 Remove the fuel injector cooling pipe (if equipped) and the rocker arm assembly.
3 Loosen the locking nuts of the adjusting screws on the valve yoke.
Turn the adjusting screws in counterclockwise direction to provide enough clearance.
4 Adjust the valve yoke.

1 Adjusting screw
2 Locking nut
3 Valve stem
4 Valve yoke
Fig 12-16 Adjusting the valve yoke

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a Press down the yoke's adjustable end.

b Tighten the adjusting screw (1) until it touches the valve stem (3).
c Mark the position A.
d Press down the yoke's fixed end.
e Tighten the adjusting screw until it touches the valve stem.
f Mark the position B.
g Turn the adjusting screw counterclockwise to the middle position C.
h Lock the valve yoke locking nut (2).

5 Check the adjustment of the valve yoke.

a Remove the valve yoke.
b Place a drop of oil on the top of each valve steam.
c Lower the valve yoke into position.
d Remove the valve yoke and check that the oil marks on the valve yoke are similar.

If one oil mark is bigger than the other, the valve yoke needs to be re-adjusted.

Postrequisites
● Mount and centralise the rocker arm assembly. See Chapter 14 Valve mechanism and
camshaft.
● Mount the fuel injector cooling pipe (if equipped).
● Check and adjust the valve clearance.

12.2.5 Adjusting the valve clearance

Prerequisites
● Disconnect the cylinder pressure sensor cable (if equipped).
● Remove the cylinder head cover.
● Rotate the flywheel to a position where the valve tappet rollers are on the base circle of the
camshaft.
● Check that the valve yoke clearance is adjusted correctly.

NOTICE
Incorrect adjustment of valve clearance may cause serious damage.

Adjust the valve clearance only after the engine has cooled down.

Tools

Code Description

848 004 Feeler gauges

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12. Cylinder head with valves Wärtsilä 20DF Engine O&MM

Procedure
1 Hit the push rod end of the rocker arm with a soft hammer to ensure that the push rod
is seated correctly.
2 Place the correct thickness feeler gauge (4) between the yoke surface and the rocker
arm shoe.

1 Rocker arm 4 Feeler gauges

2 Rocker arm adjusting screw 5 Valve yoke
3 Locking nut
Fig 12-17 Adjusting the valve clearance

Make sure to use the feeler gauge marked 'EX' for the exhaust valves, and the
feeler gauge marked 'IN' for the inlet valves.

3 Tighten the rocker arm adjusting screw (2) until the feeler gauge can be moved back
and forth only with a slight force.
4 Hold the rocker arm adjusting screw and tighten the rocker arm locking nut (3) to the
stated torque.
See Chapter 07 Tightening torques and use of hydraulic tools.
5 Check that the clearance has not changed while tightening.
See Chapter 06 Adjustments, clearances and wear limits.
6 Remove the feeler gauge.

Postrequisites
● Mount the cylinder head cover.
● Carefully guide any sensor cable(s) through the cylinder head cover.
● Connect the cylinder pressure sensor (if equipped).

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12.3 Seat rings

12.3.1 Removing the inlet and exhaust valve seat rings hydraulically
Prerequisites
Remove the cylinder head.

Tools

Code Description

834 050 Hydraulic cylinder

836 006 Cylinder head service trestle

837 036 or 837 018 Inlet valve seat ring extractor tool

837 024 Exhaust valve seat ring extractor tool

861 161 High-pressure pump

Procedure
1 Turn the cylinder head upside down.
2 Clean the inner side of the valve seat to fit the extractor tool.
3 Mount the extraction tool set.
4 Assemble the extraction tool and mount it on the valve seat rings.

The inlet and exhaust valve seats have different jaws.

NOTICE
Make sure the tool is seated correctly onto the exhaust valve seat ring. Incorrect fitting will
damage the tool and the port.

a Inlet valve seat ring:

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12. Cylinder head with valves Wärtsilä 20DF Engine O&MM

1 Hydraulic hose 4 Valve seat ring extraction tool

2 Hydraulic cylinder 5 Valve seat ring
3 Pull screw 6 High-pressure pump
Fig 12-18 Removing the inlet valve seat ring

b Exhaust valve seat ring:

NOTICE
Make sure the puller is pulling the seat ring, not the cylinder head casting material.

1 Hydraulic hose 4 Valve seat ring extraction tool

2 Hydraulic cylinder 5 Valve seat ring
3 Pull screw 6 High-pressure pump
Fig 12-19 Removing the exhaust valve seat ring

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5 Mount the hydraulic cylinder and tighten it with the pull screw.

NOTICE
Make sure the puller is pulling the seat ring, not the cylinder head casting material.

6 Connect the hydraulic hoses between the high-pressure pump and the hydraulic cylinder.
7 Remove the valve seat ring.
a Increase the pressure until the valve seat ring is loose.
b Release the pressure by opening the high-pressure pump valve.
c Disconnect the hoses of the hydraulic cylinder.
d Pull the valve seat ring out of the cylinder head together with the extraction tool.
e Remove the valve seat ring and dismantle the extraction tool.

12.3.2 Removing the valve seat rings manually

Tools

Code Description

836 006 Cylinder head service trestle

If the hydraulic extraction tool is not available, a scrapped valve can be used to
remove the seat rings.

Procedure
1 Weld a scrapped valve to the valve seat.
a Turn the cylinder head upside down.
b Clean the inner side of the valve seat.
c Machine the valve disc to a diameter of 55-60 mm to get a better welded contact
area.
d Place the scrapped valve with reduced diameter into the valve seat ring.
e Weld the scrapped valve and the seat ring together with an electric beam.

NOTICE
Protect the flame plate and the joint surfaces of the cylinder head when welding.

2 Turn the cylinder head on its side.

3 Press out the valve seat ring or knock it out by a few hammer strokes on top of the valve
stem.

NOTICE
Do not damage the valve guide.

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12. Cylinder head with valves Wärtsilä 20DF Engine O&MM

12.3.3 Fitting the inlet valve seat rings

Tools

Code Description

836 018 Cylinder head service trestle

837 033 Inlet valve seat ring assembly spindle

847 005 or 847 049 Complete cylinder head pressure test tool

847 059 Cylinder head pressure test flanges

WARNING
Liquid nitrogen, and the liquid nitrogen cooled engine parts are extremely cold and can cause
frostbites to your skin or serious injury to your eyes.
● Wear proper personal protective equipment, such as low-temperature-resistant gloves
and safety glasses.
● Read the safety measures for liquid nitrogen given by the supplier.

Procedure
1 Clean the valve seat bores in the cylinder head.
a Clean the surface gently with a grit 400 or finer emery cloth.
b Clean the surface with Loctite 7063 cleaning spray or a similar solvent.

2 Measure the valve seat ring bores.

Check the diameter in two directions at two heights and compare the diameters with nominal
dimensions. See Chapter 06 Adjustments, clearances and wear limits.

If there are scratches or corrosion marks or if the diameter is outside tolerance,

recondition the valve seat ring bores.

3 Fit a new inlet valve seat ring.

a Cool the inlet valve seat ring in liquid nitrogen to -140°C.
If nitrogen is not available, cool the seat ring in a freezer and heat the entire cylinder head
so that the seat ring to cylinder head temperature difference is at least 120°C.
b Insert the valve seat ring by pressing it in with a guided arbor or using an inlet valve.
Knock on the inlet valve using a plastic hammer until the seat ring is correctly seated.

4 When the cylinder head has reached the required room temperature, check the
eccentricity of the sealing face in relation to the valve guide.
If it exceeds 0.1 mm, grind the seat surface in a seat grinding machine.

Postrequisites
Check the contact area with the blueing test.

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12.3.4 Fitting the exhaust valve seat rings

Prerequisites
Check the condition of the valve guide.

CAUTION
Hot or cold engine parts can cause injury if in contact with the skin.
Wear proper personal protective equipment (PPE).

Tools

Code Description

836 018 Cylinder head service trestle

837 032 Exhaust valve seat ring assembly spindle

847 004 Cylinder head pressure test tool

847 005 or 847 049 Complete cylinder head pressure test tool

847 059 Cylinder head pressure test flanges

1 Sealing ring
2 Exhaust valve seat ring
Fig 12-20 Exhaust valve seat ring

Procedure
1 Clean the cylinder head bore.
a Clean the surface gently with a grit 400 or finer emery cloth.
b Clean the surface with Loctite 7063 cleaning spray or a similar solvent.

2 Measure the valve seat ring bores.

Check the diameter in two directions at two heights and compare the diameters with nominal
dimensions. See Chapter 06 Adjustments, clearances and wear limits.

If there are scratches or corrosion marks or if the diameter is outside tolerance,

recondition the valve seat ring bores.

3 Heat the cylinder head.

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a Heat the cylinder head slowly and equally up to 100°C.

b Heat the cylinder head with a gas burner, or by placing it in a closed box and heat
it with steam.

It is important that the entire cylinder head is heated, not only the valve seat ring
bore.

4 Cool the exhaust valve seat ring in a refrigerator to no lower than 0°C.
The temperature difference between the cylinder head and the seat ring should be 50–100°C.

NOTICE
Temperatures below the freezing point may damage the sealing ring during assembly.

5 Clean the entire seat ring with Loctite 7063 cleaning agent.
6 Apply Loctite 620 on the part of the seat ring with the larger diameter.
Do not apply it on the smaller diameter part where the sealing ring fits.
7 Apply Molycoat 55 grease to lubricate the sealing ring.
If not available, use soap-water solution.
8 Fit the lubricated sealing ring on the seat ring.
9 Fit the exhaust valve seat ring quickly in the cylinder head using one of the two methods:
● Put the valve seat ring into a guiding bush and press in the seat with a guided arbor. It can
also be mounted by placing the valve seat ring onto the mounting tool and immediately into
the valve seat bore.
● Insert the valve seat ring using an old scrapped exhaust valve. Knock on the valve using a
plastic hammer until the seat ring is correctly seated.

NOTICE
Mount the exhaust valve seat ring carefully, so that the seat ring seats correctly and the sealing
ring is not damaged.

10 When the cylinder head has reached the required room temperature, check the
eccentricity of the sealing face in relation to the valve guide.
If it exceeds 0.1 mm, grind the seat surface in a seat grinding machine.
11 Pressure-test the cylinder head water side.

WARNING
When the cylinder head test pressure is being raised, possible ejection of the push-in caps
may cause serious injury.
● Do not stand in front of, or bent over the push-in caps.
● Wear proper personal protective equipment, such as safety goggles during testing.

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Fig 12-21 Location of push-in caps in the cylinder head

1 Water hose
2 Plug
3 Flange
Fig 12-22 Pressure testing setup

a Connect a water hose (1).

b Use either the plug-type (2) or the flange-type (3) pressure testing tool to prevent
the water from leaking through the cylinder head.
c Apply a pressure of 10 bar.

12.4 Valve rotators

The inlet and exhaust valves are fitted with rotators. The rotators turn the valves slightly at
every valve opening stroke. This distributes the heat evenly and gives better metallic contact

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12. Cylinder head with valves Wärtsilä 20DF Engine O&MM

between the valve and the valve seat. This improves the wear patterns and considerably extends
the maintenance interval of the valves.

12.5 Cylinder pressure sensor

Cylinder pressure sensor (if equipped)
The cylinder pressure sensor is located in the cylinder head.
The sensor assembly consists of two parts:
● Cylinder pressure sensor
● Signal conditioning unit (SCU)
The cylinder pressure sensor is used on the engine to monitor cylinder pressure. The SCU
converts cylinder pressure data to a mA signal.

12.5.1 Removing the cylinder pressure sensor

Tools

Code Description

836 008 Mounting tool for cylinder pressure sensor

Procedure
1 Rotate the camshaft to a position where the valve tappet rollers are on the base circle
of the cam.
2 Remove the valve cover.
3 Remove the rocker arm assembly.
See Chapter 14 Valve mechanism and camshaft.
4 Remove the left push rod and protecting sleeve.
5 Dismount the pressure sensor (7, see Figure 12-1) using the mounting tool for cylinder
pressure sensor.

12.5.2 Mounting the cylinder pressure sensor

Procedure
1 Check the thread on the cylinder head.
If the thread is not in good condition, use an M10 x 1 thread tap.
2 Apply anti-seize paste to the sensor thread.
3 Mount the new sensor using the mounting tool for cylinder pressure sensor.
Tighten to the stated torque. For tightening torques, see Chapter 07 Tightening torques and
use of hydraulic tools.
4 Mount the push rod and protecting sleeve.
5 Mount the rocker arm assembly.
See Chapter 14 Valve mechanism and camshaft.
6 Check the valve clearance.
7 Mount the valve cover.

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Postrequisites
Start up the engine and verify the signal from the sensor.

12.6 Knock sensor

Knock sensor
The conventional accelerometer knock sensor is located on the cylinder head. Correct tightening
of the accelerometer knock sensor is very important as it affects the readings from the sensor.

NOTICE
Tighten the sensor to the stated torque, and check that the connector is properly connected.
See Chapter 07 Tightening torques and use of hydraulic tools.

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